Lattice structure valve/regulator body

ABSTRACT

A method of manufacturing a body of a fluid control apparatus using additive manufacturing, the method including forming an inner wall having an outside surface and an inside surface, an area surrounding an inlet, an area surrounding an outlet, and an area surrounding a fluid flow path, wherein the inner wall provides a fluid boundary and connects the inlet and the outlet. The method further including forming a portion of the inner wall that receives a valve seat, forming a portion of the inner wall that receives a control stem and a control element, and forming a lattice structure by depositing a solidifiable material onto the inner wall in a predetermined pattern, wherein the lattice structure is three-dimensional and includes a plurality of connected lattice members.

FIELD OF THE INVENTION

The present disclosure relates to manufacturing a body of a fluidregulator or a control valve, more specifically, manufacturing a bodyusing additive manufacturing.

BACKGROUND

Conventional manufacturing processes and techniques for manufacturingbody components of fluid regulators and control valves place design andmaterial restrictions on the body components. Die casting, or similarsuitable methods, present certain obstacles in manufacturing bodycomponents, and those obstacles are usually overcome at the expense ofthe design of the body component. For example, a designer of a valvebody is faced with the problem of getting molten metal to flow in thecasting for the desired shape and thickness of the body. In resolvingthe issues inherent in die casting, the designer is limited to a bodydesign that can actually and easily be manufactured using known methods.Current manufacturing methods require additional finishing processes,adding to the costs of labor and materials.

Limited to conventional methods of manufacturing, a typical regulatorbody or valve body is made of a single material at a uniform density. Tomeet certain strength requirements, the body wall is often given acertain thickness to provide the strength required by the control systemto sustain highly pressurized fluids. Thus, regulator and valve bodiesare often heavy and provide strength by increasing the thickness of thebody wall.

A typical valve regulator 10, as illustrated in FIG. 1, regulates thefluid pressure and/or flow to maintain a selected output pressure, andis generally well known in the art. The fluid regulator 10 includes aregulator body 12, a control element 14, and an actuator assembly 16.The regulator body 12 defines a fluid flow path 18 that extends from afluid inlet 20 to a fluid outlet 22. The fluid regulator 10 includes anorifice 24 disposed in the fluid flow path 18 and leading to a valveseat 26. The control element 14 is disposed within the fluid flow 18path and is shiftable between an open position (as shown in FIG. 1) inwhich the control element 14 is spaced away from the valve seat 26, anda closed position in which the control element 14 is seated against thevalve seat 26. The actuator assembly 16 is attached to or otherwiseoperatively coupled to the control element 14 and is arranged to respondto fluid pressure changes in the outlet 22 and to move the controlelement 14 between the open position and the closed position in order tocontrol the flow of the process fluid through the orifice 24. Theactuator assembly 16 may be conventional and may include a diaphragmassembly 28, load springs 30, and a suitable stem 32 or other suitablelinkage. The actuator assembly and diaphragm assembly are enclosed in ahousing 34 which is attached to the regulator body 12.

An inner wall 36 of the regulator body 12 provides an area 38surrounding the inlet 20, an area 40 surrounding the outlet 22, aportion 42 defining the fluid flow path 18, an area 43 surrounding acylindrical bore 44 to receive the control element 14, and a portion 46to receive the valve seat 26. The inner wall 36 of the conventionalfluid regulator 10, such as the one depicted in FIG. 1, provides auniform density of a single material, typically metal or plastic,including brass, bronze, cast iron, steel, alloy steels, and stainlesssteels, or other suitable materials.

Accordingly, it may be desirable to provide a method of manufacturing abody for fluid regulators and control valves where the manufacturingprocess is driven by design, rather than the design of the body beingdriven by the manufacturing process. Manufacturing a valve body or aregulator body that may be light, stable, and capable of withstandingpressure of a typical valve body or regulator body is also desirable.

SUMMARY

In accordance with one or more exemplary aspects, a valve and/orregulator body assembled in accordance with the teachings disclosedherein may address the limitations of current manufacturing processes byutilizing Additive Manufacturing (AM), Laser-Sintering, and/orthree-dimensional printing for designing and manufacturing valve andregulator bodies. AM eliminates the restrictions placed on design byconventional manufacturing practices, and allows manufacturing anddesign of a regulator or valve body including one or more differentmaterials, varying densities, and other material parameters based on therequirements of the body.

In accordance with a first exemplary aspect, a method of manufacturing abody of a fluid control apparatus using additive manufacturing isdisclosed herein. The method includes forming an inner wall having anoutside surface and an inside surface, an area surrounding an inlet, anarea surrounding an outlet, and an area surrounding a fluid flow path,wherein the inner wall provides a fluid boundary and connects the inletand the outlet; forming a portion of the inner wall that receives avalve seat; forming a portion of the inner wall that receives a controlstem and a control element; forming a lattice structure by depositing asolidifiable material onto the inner wall in a predetermined pattern,wherein the lattice structure is three-dimensional and includes aplurality of connected lattice members.

In accordance with a second exemplary aspect, a method of manufacturinga body of a fluid control apparatus, the method including: forming aninner wall having an inside surface and an outside surface; forming aportion of the inner wall arranged to receive a valve seat; forming afirst flange surrounding an inlet, a second flange surrounding anoutlet, and a portion surrounding a fluid flow path connecting the inletand the outlet; forming a portion of the inner wall surrounding a borethat receives a control element and a valve stem; and forming a latticestructure having a plurality of connected lattice members, wherein thelattice structure is attached to the inner wall.

In accordance with a third exemplary aspect, a body of a fluid controlapparatus, the body comprising: an inner wall of a first densityincluding an outside surface, an inside surface, an area surrounding abore sized to receive a control stem and a control element, an areasized to receive a valve seat, a first flange surrounding an inlet, asecond flange surrounding an outlet, and an area defining a fluid flowpath connecting the inlet and the outlet; and a lattice structure of asecond density attached to the inner wall. Further including the step ofproviding a housing arranged to receive an actuator assembly and adiaphragm assembly, wherein the housing is configured to attach to theinner wall.

In further accordance with any one or more of the foregoing first,second, or third aspects, a body and/or method may further include anyone or more of the following preferred forms. In a preferred form, themethod includes depositing the solidifiable material directly onto theinside surface of the inner wall.

In a preferred form, the method of includes depositing the solidifablematerial directly onto the outside surface of the inner wall.

In a preferred form, the method includes forming a hollow space betweenthe outside surface and the inside surface of the inner wall.

In a preferred form, the method includes depositing a solidifiablematerial onto the inner wall within the hollow space.

In a preferred form, the method includes the step of depositing thesolidifiable material to form the lattice structure and a shell, whereinthe lattice structure is disposed within the shell.

In a preferred form, the method includes forming the lattice structureon a receiving surface, removing the lattice structure from thereceiving surface, and attaching the lattice structure to the innerwall.

In a preferred form, the method includes additive manufacturing theinner wall and the lattice structure together by depositing asolidifiable material in a predetermined pattern to create athree-dimensional integrated body.

In a preferred form, the method includes manufacturing the latticestructure and attaching the lattice structure to the inside surface ofthe inner wall to modify the fluid flow path.

In a preferred form, the method includes manufacturing the latticestructure and attaching the lattice structure to the outside surface ofthe inner wall.

In a preferred form, the method further including the step ofidentifying a material property requirement of a localized area of theinner wall, and providing the lattice structure to the localized area,wherein the lattice structure includes the material property requirementof the localized area.

In a preferred form, the method further including the step of providingthe lattice structure to the localized area wherein the localized arearequires a low material strength requirement.

In a preferred form, the method of claims further including the step ofreinforcing the lattice structure by providing at least one link betweenat least two of the plurality of lattice members.

In a preferred form, the method includes the step of disposing theplurality of lattice members at a predetermined distance to achieve apredetermined density of the lattice structure.

In a preferred form, the method further including forming a non-uniformlattice structure density by disposing the plurality of latticestructure members are varying distances.

In a preferred form, the method includes connecting the plurality oflattice members at a predetermined distance to achieve a predetermineddensity of the lattice structure.

In a preferred form, the method further including the step of providinga nonporous material for the inner wall and a porous material for thelattice structure.

In a preferred form, the method further including the step of providinga gel, gas, or fluid disposed within the lattice structure forinsulation.

In a preferred form, the method further including the step of providinga sensor disposed within the lattice structure for sensing changes inflow characteristics.

In a preferred form of the body, the lattice structure and the innerwall are integrally attached.

In a preferred form of the body, the lattice structure is attached tothe inside surface of the inner wall.

In a preferred form of the body, the lattice structure is attached tothe outside surface of the inner wall.

In a preferred form of the body, the inner wall is a shell having ahollow space and the lattice structure is attached to the shell withinthe hollow space.

In a preferred form of the body, the second density of the latticestructure varies by varying the distance between connected latticemembers of the plurality of connected lattice members.

In a preferred form of the body, the lattice structure is a firstmaterial and the inner wall is a second material.

In a preferred form of the body, the lattice structure includes at leastone link connecting at least two of the plurality of lattice members.

In a preferred form of the body, the lattice structure has variablestrength by varying a thickness of the link.

In a preferred form of the body, the lattice structure is attached tothe inner wall by welding.

In a preferred form, the body further includes a sensor, gel, or inertgas disposed within the lattice structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross-sectional view of a known fluid regulator.

FIG. 2 illustrates a cross-sectional view of a regulator or valve bodyand lattice structure assembled in accordance with the teachings of afirst exemplary arrangement of the present disclosure.

FIG. 3 illustrates a cross-sectional view of a regulator or valve bodyand lattice structure assembled in accordance with the teachings of asecond exemplary arrangement of the present disclosure.

FIG. 4A illustrates a cross-sectional view of a regulator or valve bodyand lattice structure assembled in accordance with the teachings of athird exemplary arrangement.

FIG. 4B illustrates a top, cross-sectional view of the body and latticestructure of FIG. 4A.

FIG. 5 illustrates a front view of the lattice structure of FIGS. 4A and4B.

FIG. 6A is an enlarged fragmentary cross-sectional view illustrating afirst exemplary arrangement of two lattice members of a latticestructure assembled in accordance with the teachings described herein.

FIG. 6B illustrates an enlarged fragmentary cross-sectional viewillustrating a second exemplary arrangement of two lattice members of alattice structure assembled in accordance with the teachings describedherein.

FIG. 6C illustrates an enlarged fragmentary cross-sectional viewillustrating an exemplary arrangement of three lattice members assembledin accordance with the teachings described herein.

DETAILED DESCRIPTION

Turning now to specific examples of the drawings, FIGS. 2-4B illustratea method and an apparatus for manufacturing a regulator body or a valvebody by one or more of Additive Manufacturing (AM), Laser-Sintering,stereolithography, and/or industrial three-dimensional printing.

Referring now to FIG. 2, a body 112 for a fluid regulator or a controlvalve may be at least partially manufactured by AM. The body 112 mayreplace the body 12 of the fluid regulator 10 of FIG. 1 or a body of acontrol valve. The body 112 includes an inner wall 136 including an area138 surrounding a fluid inlet 120, which may include a first flange, anarea 140 surrounding a fluid outlet 122, which may include a secondflange, and an area 142 defining a fluid flow path 118 that connects theinlet 120 and the outlet 122. The inner wall 136 includes an area 143surrounding a cylindrical bore 144 that is sized to receive a controlstem and a control element. The inner wall 136 may include an area 146sized to receive a valve seat that is disposed between the inlet 120 andthe outlet 122 within the flow path 118. The inner wall 136 includes aninside surface 148 and an outside surface 150.

The body of FIG. 2 includes at least one lattice structure 152 includinga plurality of connected lattice members 154 formed by AM or othersuitable methods. The lattice structure 152 and the inner wall 136 maybe integrally attached. The lattice structure 152 is attached to theoutside surface 150 of the inner wall 136 at the area 138 surroundingthe inlet 120, the area 140 surrounding the outlet 122, the area 142defining the fluid flow path 118, and at least part of the area 143surrounding the bore 144. The lattice structure 152 may be porous havinga density that differs from the density of the inner wall 136. Asdescribed in more detail below, the lattice structure 152 is made of aplurality of connected lattice members 154 arranged in connected latticecell units to form a three-dimensional structure. Air pockets may beformed between the lattice members 154, providing a lighter and lessdense body 112. Due to the structural similarities of FIGS. 2-6, onlynew components will be given new reference numbers.

The body 112 of FIG. 2 may be designed specifically to suit the needs ofthe fluid control apparatus or system for which it is made. The latticestructure 152 illustrated in FIG. 2 is attached to the outside surface150 of the inner wall 136 to provide support for the inner wall 136 andto reduce the weight of the body 112. In this example, the latticestructure 152 is disposed on the outside surface 150 of the inner wall136 so that the process fluid does not interact with the latticestructure 152. The inner wall 136 may provide a non-permeable barrierbetween the outside surface 150 of the inner wall 136 and the processfluid. In case of a leak in the inner wall 136, the lattice structure152 may be equipped with a sensor that may detect a leak, break, orvibrations in the inner wall 136.

Focusing now on the area 142 of the inner wall 136 that surrounds thefluid flow path 118, the inner wall 136 has a thickness t that is lessthan a thickness of the inner wall 36 of the body 12 of FIG. 1. Thelattice structure 152 may add to the overall thickness of the body 112,but the thickness of the solid, nonporous inner wall 136 is reduced,thereby reducing the overall weight of the body 112. Although thelattice structure 152 may be less dense and may be porous, the structure152 may be designed to provide structural support specifically for thearea of the inner wall 136 to which it is attached. The latticestructure 152 may be manufactured by AM integrally with or separatelyfrom the inner wall 136 of the body 112. Preferably, the latticestructure 152 and the inner wall 136 of the body 112 are designedtogether as a three-dimensional model and then manufactured as a singlebody 112 by AM, or more specifically, direct metal laser sintering(DMLS). The lattice structure 152 of FIG. 3 may be the same or differentmaterial than the inner wall 136 and may be the same or differentdensity than the inner wall 136. The lattice structure 152 may beattached to the inner wall 136 by welding, bonding, or by other means.

Turning now to FIG. 3, at least one lattice structure 152 is attached tothe inside surface 148 of the inner wall 136 and the outside surface 150of the inner wall 136 may be non-porous and uniform. The latticestructure 152, due to its porosity, may be attached or formed directlyon the inside surface 148 of the inner wall 136 to modify the fluid flowpath 118, and therefore, modify the flow of the process fluid throughthe body 112. For example, process fluid may be free to flow within thespace and/or air pockets of the lattice structure 152, which mayredirect or diffuse the flow of the process fluid through the body 112.Similar to the body 112 of FIG. 2, the body 112 of FIG. 3 may be lighterin weight and may provide a non-uniform density than the conventionalbody 12 of FIG. 1. The area 138 surrounding the inlet 120, the area 142defining the fluid flow path 118, the area 143 surrounding bore 144, andthe area 146 shaped to receive a valve seat are at least partiallyformed by the lattice structure 152. The area in which the latticestructure 152 replaces the inner wall 136 may be determined byconducting a finite element analysis as described in further detailbelow. The lattice structure 152 disposed on the inside surface 148 ofthe inner wall 136 may be arranged such that the flow of the processfluid is a function of the structure and connections of the latticemembers.

FIGS. 4A and 4B illustrate a third exemplary body 112 wherein the innerwall 136 is a hollow shell 160 having a hollow space 162 between a firstinside surface 164 of the shell 160 and a second inside surface 166 ofthe shell 160. The lattice structure 152 is disposed or otherwiseattached within the hollow area 162 to the first inside surface 164 andthe second inside surface 166 of the shell 160. FIG. 4B illustrates atop view of cross-section A-A of FIG. 4A. The lattice structure 152 maybe disposed throughout the inner wall 136 of the body 112, but remainsinsulated by the outside and inside surfaces 150, 148 of the inner wall136. In this case, the body is much lighter in weight than theconventional body 12 of FIG. 1. The lattice structure 152 may vary indensity throughout the body 112 to add structural support, distributestress, and add strength to certain areas of the body 112. The latticestructure 152 may be made separately and then placed within the hollowspace 162 of the shell 160, or the lattice structure 152 may be directlyformed on the inner wall 136 by AM, i.e. deposited by successive layersof solidifiable materials.

FIG. 5 illustrates a front view of the lattice structure 152 of FIGS. 4Aand 4B without the shell 160 of the body 112. The lattice structure 152in FIG. 5 is uniform, but may be designed having a non-uniform densitywhere some areas of the lattice structure 152 provide highlyconcentrated lattice cell units, i.e. more connected lattice members154, or may provide thicker lattice members 154 in certain areas tostrengthen weaker areas of the body 112. The lattice structure 152 mayreplace parts of the body 112 as shown in FIGS. 2-3, or the latticestructure 152 may substantially form the inner wall 136, including thearea 138 surrounding the inlet 120, the area 140 surrounding the outlet122, the area 142 defining the fluid flow path 118, the area 143surrounding the bore 144, and other parts of the body 112. The shape ofthe lattice structure 152 may be designed to form a structure of anyregulator or valve body, and is not limited to the lattice structure 152of FIG. 5. In a preferable arrangement, the shell 160 and the latticestructure 152 are manufacturing using DMLS where a hole 168 is formed inthe shell 160 and the lattice structure 152 so that excess powder usedin the process may be removed. The hole 168 would then be sealed with aweld or a fitting. The hole may be a conduit for introducing a gel, gas,or a liquid into the body. In contrast, the body 112 of FIG. 3 may notrequire a hole to be formed during the manufacturing process because theexcess powder from manufacturing may easily be removed from the bore144, the inlet 120, or the outlet 122.

Turning now to FIG. 5 and FIGS. 6A-6C, the lattice members 154 areinterconnected to form the lattice structure 152 as illustrated herein.The plurality of lattice members 154 form a pattern of connected latticeunit cells 169 that may repeat a certain pattern to provide the overalllattice structure 152. In the illustrated example, the lattice unit cell169 is a cubic cell where at least twelve lattice members are connectedin a three-dimensional space. Each lattice member 154 is connected toanother lattice member 154 at a 90 degree angle, and each member isspaced apart from a similarly situated parallel lattice member 154 apredetermined distance apart. Cross-section B-B of the uniform latticestructure 152 of FIG. 5 is similar, or substantially similar, to across-section that is orthogonal to B-B. In other words, the cubiclattice cell 169 is uniform throughout the lattice structure 152,providing parallel lattice members 154 connected to perpendicularlattice members 154 in three-dimensions. At any point, the lattice cellunit 169 remains the same or substantially the same.

FIG. 5 is merely an example of a three-dimensional lattice structure152, and the lattice structure 152 described herein may be any one of avariety of combinations of connected lattice members 154. For example,the lattice members 154 may be connected at varying angles, spaced apartat varying distances, and may include different lengths and thicknesses.The entire structure 152 may be uniform as illustrated in FIG. 5, or thelattice structure 152 may be non-uniform, with specific densities at apredetermined localized areas of the body 112. In some examples, thelattice cell units 169 may vary in density, forming a lattice structure152 having a non-uniform density. The density of the lattice structure152 may vary by varying a distance between connected lattice members154. The lattice structure 152 may provide strength where needed byreducing the distance between members 154 and may reduce weight wherestrength is not needed by increasing the distance between members 154.

Section B-B of FIG. 5 is partially illustrated in FIG. 6A, depicting across-section of a partial lattice cell unit 169 in a two-dimensionalx-y plane including first and second lattice members 154, 170. Themembers 154, 170 are parallel and are attached or otherwise connected toa perpendicular receiving surface 172. The receiving surface 172 may bea third lattice member 154, the inside or outside surface 148, 150 ofthe inner wall 136 of the body 112, or other surface. A reinforcementlink 174 of a predetermined radius r connects the first member 154 tothe receiving surface 172 on at least one side 176 of the lattice member154. A second reinforcement link 174 connects the second member 170 onat least one side 176 to the receiving surface 172. The reinforcementlink 174 provides structural support and reinforcement to the latticecell unit 169, and therefore to the lattice structure 152. FIG. 6Billustrates another arrangement of first and second lattice members 154,170 and a reinforcement link 178 having a radius R that connects thefirst lattice member 154 to the receiving surface 172 and to the secondparallel lattice member 170. The strength of the lattice structure 152may vary according to the variable thickness of the reinforcement link174, 178. The reinforcement link 178 in this case is an arc, but may berectangular, or of another geometry.

As illustrated in FIG. 6C, the lattice structure 152 may provide addedstructural support or strength by disposing the lattice members 154closer together per lattice cell unit 169. The lattice member 154 isspaced a distance d from the second lattice member 170, which is lessthan a distance f between lattice members 154, 170 in FIG. 6B. Bydisposing the lattice members 154 at shorter distances, each latticecell unit 169 increases in density. The lattice structure 152 mayprovide a first density in one area where the lattice members 154 aredisposed a distance f, such as the lattice members 154, 170 of FIG. 6B,or the members 154 may be placed apart a distance d for a second andgreater density. Shorter distances between lattice members 154 andreinforcement members 174, 178 may alleviate stress risers and provideadded support to those areas of the body 112. The design of the latticestructure 152 may be adjusted and customized by adjusting thethree-dimensional model of the body 112 in order to provide lattice cellunits 169 having varying lattice member thickness, length, disposed atvarying distances, connected at varying angles, and supported bydifferent reinforcement links 174, 178. Additionally, the lattice cellunit 169 may be cubic, trinclinic, monoclinic, orthorhombic, tetragonal,rhombohedral, or hexagonal.

In a preferred method, the body 112 may be manufactured by AM with alattice structure 152 as an integral piece. For example, a methodmanufacturing a body 112 as described and illustrated herein, mayinclude forming an inner wall 136 having an outside surface 150 and aninside surface 148, an area 138 surrounding an inlet 120, an area 140surrounding an outlet 122, and an area 142 surrounding a fluid flow path118, wherein the inner wall 136 provides a fluid boundary and connectsthe inlet 120 and the outlet 122. The method may further include forminga portion 146 of the inner wall 136 that receives a valve seat, forminga portion 143 of the inner wall that receives a control stem and acontrol element, and forming a lattice structure 152. Forming thelattice structure 152 may include depositing a solidifiable materialonto the inner wall 136 in a predetermined pattern, wherein the latticestructure 152 is three-dimensional and includes a plurality of connectedlattice members 154. The lattice structure 152 as illustrated in FIGS.2-5 may be formed by directly depositing the solidfiable materialdirectly on the outside surface 150 of the inner wall 136 (FIG. 2), theinside surface 148 of the inner wall 136 (FIG. 3), or to the inner wall136 within the hollow space 162 of the shell 160 (FIG. 4A-4B). Thesolidifiable material may be a fine powder of metal, composite, orpolymer that bonds with other deposited layers by sintering or othersuitable methods.

To reduce the weight of a valve body or regulator body, the method mayfurther including performing a FEA to minimize the amount of thematerial, to optimize the use of risers or support structures incritical areas of the body 112, and the use of lighter materials. Inaddition to providing a lighter body 112, a lattice structure 152 mayprovide structural support by redistributing stress in the body 112. AnFEA of the body 112 may help effectively optimize the use of a latticestructure 152 in the body 112 and to effectively design a latticestructure 152 for a particular location in the body 112. Results fromthe FEA may identify areas of the body 112 that are subject tosubstantial stress, pressure, force, or other measurable materialproperties. Similarly, areas that do not provide support or that do notrequire material properties related to strength can be identified.According to the results of the FEA, a designer may determine whichareas of the body that can be replaced with a lattice structure 152.More specifically, the designer may design a lattice structure 152 thatdistributes stress, supports the inner wall 136, and reduces overallbody weight to be implemented in the body 112. For example, a FEA maydetermine that certain areas of the body 112 do not require a particularstrength inherent in a body 112 of a certain thickness and material.Once that area is determined, a three-dimensional model of the body 112and lattice structure 152 designed particularly for that localized areamay be provided. In another example, the inner wall 136 of the body 112may be manufactured using conventional processes, and then milled orotherwise shaped to provide a receiving surface 172 for the latticestructure 152.

The lattice structure 152 may be attached to the inner wall 136 bywelding, bonding, or other suitable means, or it may be manufactureddirectly onto a surface of the inner wall 136 by AM. As illustrated inFIGS. 2-4B, the lattice structure 152 may be attached or otherwiseprinted on the inside surface 148, outside surface 150, or on the firstand second inside surfaces 164, 166 of the hollow shell 160. The latticestructure 152 may be formed by depositing the solidifiable material on areceiving surface, removing the lattice structure 152 from the receivingsurface, and attaching the lattice structure to the inner wall 136. Thebody 112 may be manufactured as a single three-dimensional integratedbody 112 or may be manufactured as separate parts and then combined toform a single body. The inner wall 136 may be first casted using knownmethods and then the lattice structure 152 may then be attached to theinner wall. The body 112 illustrated and described herein may be adaptedand configured to couple to or otherwise connect to other parts of acontrol valve or fluid regulator.

The lattice structure 152 may form various shapes, densities, andstrengths to suit the needs of the body 112. The lattice structure 152may be a first material and the inner wall 136 may be a second material.The body 112 may be made of one or multiple materials based on the needsof the body 112, such as strength, flexibility, insulation, etc., andmay be partially manufactured by conventional methods and/or by additivemanufacturing. The inner wall 136 and the lattice structure 152 may bethe same or different materials. For example, the inner wall 136 may bea material that is resistant to the process fluid, and the latticestructure 152 may be a different material than the inner wall 136 thatprovides strength. The lattice structure 152 may be a permeable, nonpermeable, and/or may have a varying shapes and lattice structureformations. The air pockets of the lattice structure 152 may be sealedwith an inert gas, gel, or fluid for insulation or to prevent chemicalsfrom the process to leak through the inner wall 136 and break down thebody 112. A sensor may be placed within the lattice structure 152 todetect leaks or vibrations in the inner wall 136. The sensor may beconfigured to direct flow away from an inner wall break or in aparticular manner. The sensor may also remove, reduce, or otherwisechange temperature of the process fluid.

Upon reading the disclosure above, those skilled in the art wouldunderstand that conventional methods of manufacturing a body componentof fluid control systems may only provide a body with uniform density,providing strength by forming thick walls of a single suitable material.Incorporating a lattice structure formed by Additive Manufacturingdeviates from current practice because the design of the body drives theprocess of manufacturing, rather than the process driving the design.The lattice structure may be designed having a shape and structurecapable of redistributing the stress of the body and providingadditional structural support. For bodies incorporating a latticestructure as part of the inner wall of sizes 6″ or larger, the body maybe significantly be lighter in weight than a body manufactured byconventional methods.

Additionally, the skilled person would understand that AM may utilizeany number three-dimensional printers or AM machines that are availableand that are suitable for making and designing a regulator body or avalve body in accordance with the present disclosure. AdditiveManufacturing enables a design-driven manufacturing process such thatthe body components of fluid control systems are manufactured based onthe design requirements, and not based on the restriction and limitedcapabilities of manufacturing methods. AM affords design flexibility,integration of new materials and structures, and customization of bodycomponents. AM may be used for designing light, stable, customizable andcomplex structures, thereby saving a manufacturer costs related to laborand materials associated with finishing processes. Additivemanufacturing allows each valve body to be customized according to therequirements of the process for which it is used.

1-33. (canceled)
 34. A method of manufacturing a body of a fluid controlapparatus using additive manufacturing, the method including: forming aninner wall having an outside surface and an inside surface, an areasurrounding an inlet, an area surrounding an outlet, and an areasurrounding a fluid flow path, wherein the inner wall provides a fluidboundary and connects the inlet and the outlet; forming a portion of theinner wall that receives a valve seat; forming a portion of the innerwall that surrounds a bore and receives a control stem and a controlelement; forming a three-dimensional lattice structure by depositing asolidifiable material onto the inner wall in a predetermined pattern,wherein the lattice structure includes a plurality of connected latticemembers.
 35. The method of claim 34, wherein depositing the solidifablematerial includes depositing the solidifiable material directly onto theinside surface of the inner wall.
 36. The method of claim 34, whereindepositing the solidifable material includes depositing the solidifablematerial directly onto the outside surface of the inner wall.
 37. Themethod of claim 34, wherein forming the inner wall includes the of stepforming a hollow space between the outside surface and the insidesurface of the inner wall.
 38. The method of claim 37, wherein formingthe lattice structure includes depositing a solidifiable material ontothe inner wall within the hollow space.
 39. The method of claim 34,further including the step of identifying a preferred material propertyof a localized area of the inner wall, and providing the latticestructure to the localized area, wherein the lattice structure includesthe preferred material property of the localized area.
 40. The method ofclaim 39, further including the step of providing the lattice structureto the localized area wherein the localized area requires a low materialstrength requirement.
 41. The method of claim 34, further including thestep of reinforcing the lattice structure by providing at least one linkbetween at least two of the plurality of lattice members.
 42. The methodof claim 34, wherein the step of forming the lattice structure includesconnecting the plurality of connected lattice members a predetermineddistance apart to achieve a predetermined density of the latticestructure.
 43. A method of manufacturing a body of a fluid controlapparatus, the method including: forming an inner wall having an insidesurface and an outside surface; forming a portion of the inner wallarranged to receive a valve seat; forming a first flange surrounding aninlet, a second flange surrounding an outlet, and a portion surroundinga fluid flow path connecting the inlet and the outlet; forming a portionof the inner wall surrounding a bore that receives a control element anda valve stem; and forming a lattice structure having a plurality ofconnected lattice members, wherein the lattice structure is attached tothe inner wall.
 44. The method of claim 43, wherein depositing thesolidifiable material includes forming the lattice structure on areceiving surface, removing the lattice structure from the receivingsurface, and attaching the lattice structure to the inner wall.
 45. Themethod of claim 43, wherein forming the inner wall includes forming theinner wall and the lattice structure together by depositing asolidifiable material in multiple layers according to a predetermineddesign to create a three-dimensional integrated body.
 46. The method ofclaim 43, wherein forming the lattice structure includes manufacturingthe lattice structure and attaching the lattice structure to the insidesurface of the inner wall to modify the fluid flow path.
 47. The methodof claim 43, wherein forming the lattice structure includesmanufacturing the lattice structure and attaching the lattice structureto the outside surface of the inner wall.
 48. The method of claim 43,further including the step of providing a nonporous material for theinner wall and a porous material for the lattice structure.
 49. Themethod of claim 43, further including the step of providing a gel, gas,or fluid disposed within the lattice structure for insulation.
 50. Themethod of claim 43, further including the step of providing a sensordisposed within the lattice structure for sensing a leak in the innerwall.
 51. The method of claim 43, further including the step ofproviding a housing arranged to receive an actuator assembly and adiaphragm assembly, wherein the housing is configured to attach to theinner wall.
 52. A body of a fluid control apparatus, the bodycomprising: an inner wall including an outside surface, an insidesurface, an area surrounding a bore sized to receive a control stem anda control element, an area sized to receive a valve seat, an areasurrounding an inlet, an area surrounding an outlet, and an areadefining a fluid flow path connecting the inlet and the outlet; and alattice structure attached to the inner wall, wherein the latticestructure includes a plurality of connected lattice members.
 53. Thebody of claim 52, wherein the lattice structure and the inner wall areintegrally attached.
 54. The body of claim 52, wherein the latticestructure is attached to the inside surface of the inner wall.
 55. Thebody of claim 52, wherein the lattice structure is attached to theoutside surface of the inner wall.
 56. The body of claim 52, wherein theinner wall is a shell having a hollow space and the lattice structure isattached to the shell within the hollow space.
 57. The body of claim 52,wherein the lattice structure includes a non-uniform density, whereinthe non-uniform density varies by varying a distance between connectedlattice members of the plurality of connected lattice members.
 58. Thebody of claim 52, wherein the lattice structure is a first material of afirst density and the inner wall is a second material of a seconddensity.
 59. The body of claim 52, wherein the lattice structureincludes at least one link connecting at least two of the plurality oflattice members, and wherein the lattice structure has variable strengthby varying a thickness of the link.
 60. The body of claim 52, furtherincluding a sensor, gel, or inert gas disposed within the latticestructure.